Take great care with the hold switch ribbon cable. I've broken two up to now. It has the strength of a piece of 2mm wide bathroom tisue. Also has a right angle bend so it willl tear more easily. You will find two very small screws holding the switch to the small metal bracket. Don't remove them - just slacken them and slip the switch off as the holes are slotted. This frees the large metal top piece and you have less weight hanging on that ribbon. Incidentally, if you do have the bad luck to tear the cable all is not lost as the lock position is with the switch closed (shorted).

It is not removed by rotation. There are two spots holding it in, one on the top (menu) and one on the bottom (play/pause). The one on the bottom is put underneath the rectangular protrusion from the bottom metal bezel (the thing around the dock connector). Once you remove the metal bezel, then the click wheel should just lift out, although like Rick said there is a small amount of glue so you may need to use a spudger.

Click wheel: I have found traces of adhesive here on a metal rim about 0.5mm wide which is part of the machined case. This rim is then cut away into four 1cm long pieces. One at 10 oclock, 4 oclock, 8 oclock and so on. Not much adhesive - but don't underestimate - it's very strong stuff. At the top of the clickwheel (at 12 oclock) is a small metal tab which slides under the ipod body. When prying out the clickwheel, lift from the bottom, otherwise you are pulling against this metal tab as well as the adhesive. Some heat on this area helps to release the adhesive. Don't end up with the metal plate under the clickwheel looking like a potato chip as happpend with my first teardown.

Does anyone know where you could get the glass replaced, my had what looked to be a scratch went to rub off and the glass shattered/cracked, and of course being the consumer and customer I'm out of luck apparently....

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Removing the internals... It's a tight squeeze, but we got them out. Getting this iPod open wasn't easy. We don't recommend trying this at home. Take great care not to scratch the screen on the sharp recess for the click wheel, bend up slightly if necessary.

We wish Apple would put a little effort into making iPods repairable, instead of forcing people to throw them away when they break. Recent iPods have become increasingly difficult to successfully repair.

This iPod employs copious amounts of glue and adhesive to hold everything together. That makes it easy for Apple to put together, but hard to take apart.

Any idea whether the adhesives and glues used in the Nano are designed to withstand repeated exposure to high humidity as often happens when people strap the device against their body while exercising? I owned a Nano Gen 3 that stopped working after only a couple months. Other people at my gym using their Nano the same way I do reported the same problem with their Gen 3. I never had problems with the Gen 1 or 2 and have no experience with Gen 4.

You don't have to throw away an old iPod...you can use the Apple Recycling Program and take your iPod to a retail store and trade it in and get 10% off your new iPod...as long its got nothing wrong with the battery...

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Missing a step on how-to remove the metal frame. Takes a fairly bit of effort to disassembly all attached objects of the frame before you are able to lift the 'mainboard' with battery attached out of it.

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The new nano features a larger display (2.2" and 240x376). This is the same width as the 4th Generation nano, but 56 pixels taller. On a pixel basis, that's 17.5% more screen real estate.

Apple keeps putting bigger screens in the same size devices. The footprint of the iPod nano has stayed the same over the last four years, but this display has four times the pixels of the original nano.

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The battery. Apple warns you right from the get-go that your iPod may melt and/or spontaneously combust: "Potential for fire or buring." We assume they mean burning. It is assembled in China, so we'll give them a little slack.

Cutting these batteries with a sharp knife produces neat looking sparks all around the blade. Between the layers of the foil in the battery is a clear slimy/lumpy substance, akin to semi dried alcohol hand sanitizer.

Where are the water contact indicators in the 5G? Are they the white dots seen in some of these steps? I know there's one in the headphone jack, but I have yet to see a picture of it to compare mine too.

I was about to make the same comment, noticed that right away. It is a bit scary when even the experts have trouble opening these things intact 0.0 I guess Apple's so hellbent on making these things thinner they sacrifice serviceability. I wonder what their yields and raw production costs are like? Their computers are much easier to work on, even if the iMac does require a big suction cup to pull the glass panel off..

Hey, but what about axelerometer? Apple was remove it from iPod nano 5G? Or we still can shake nano for next song?

It's still in there, that's how the shake to shuffle feature works. Also, is can detect which way the ipod it turned and put video in that direction (left or right from its usual upright position), and it can decide whether to record video in portrait or landscape mode.